Method for processing at least two starting materials

ABSTRACT

A method is provided for processing at least two starting materials into a final processed product where a predetermined moisture interval is provided for each starting material. The method comprises subdividing each moisture interval into two or more moisture classes and measuring a moisture content for each starting material prior to processing. Each starting material is then assigned to one of the two or more moisture classes and processed depending on the assigned moisture class. A moisture measurement of the final processed product is determined and one or more processing steps are adapted based on the measuring results for the final processed product to achieve a homogeneous moisture distribution in the final processed product.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage application pursuant to 35 U.S.C. § 371 of International Application No. PCT/EP2019/085637, filed on Dec. 17, 2019, which claims priority to, and benefit of, German Patent Application No. 10 2019 105 417.6, filed Mar. 4, 2019, the entire contents of which are hereby incorporated by reference.

FIELD OF TECHNOLOGY

The present disclosure relates to a method for processing at least two starting materials into an output material. In the disclosed processing method, a predetermined moisture interval is maintained for each of the starting materials. In the method, the starting materials are processed whose moisture originates from the predetermined moisture interval. Starting materials in this case can be materials of different substances as well as materials of the same substance that differ in terms of their moisture content, for example because they originate from different bales or other preforms. The method can be a production or a mixing method.

BACKGROUND

Processes for processing at least two starting materials are found in various technical fields; for example, the (primary) preparation of tobacco is such a process. Several starting materials with a predefined moisture content are also processed with each other when processing other natural substances such as for example cotton, cocoa, tea, etc. In the primary processing of tobacco, for example the moisture content of the different tobacco types are jointly adapted to each other in an intermediate step through a moistening process. Moisture, moisture content and moisture values will be used synonymously in the following, wherein these quantities always relate to a relative amount [%] of moisture in a solid or in another medium. Only when it is expressly noted do the amounts of moisture refer to absolute weights.

A method has been disclosed in U.S. Pat. No. 6,107,809 for determining the moisture content of tobacco material in which a tobacco material is irradiated by using microwaves, and its moisture content is determined.

A method and a device for regulating the moisture content of tobacco materials is known from CN 10568058. The method provides measuring the tobacco material using an online moisture measurement detector. The output material is processed for a fixed standard moisture value while the tobacco material that does not correspond to the standard moisture value is either dried or heated.

BRIEF SUMMARY OF THE INVENTION

The object of the invention is to improve the quality of the product at the end of processing when processing starting materials for which a predetermined moisture interval is provided.

In an embodiment, a method is provided for processing at least two starting materials. The at least two starting materials are processed in the method into a single product. For the method, a moisture content of each of the starting materials is measured. The starting materials are permitted for processing whose moisture content lies within the pre-determined moisture interval. According to the invention, it is provided that each moisture interval is subdivided into two or more moisture classes. Each of the moisture classes defines a range of values for the moisture content of the starting material within the moisture interval. Furthermore, the solution according to the invention provides that a moisture content of each starting material is measured before treating. Corresponding to the measured moisture content, precisely one moisture class is assigned to each starting material for the subsequent process. According to the invention, with respect to the starting materials, it is provided that they are processed corresponding to their moisture class. This means that the process with its method steps or parameters in the context of the process is chosen corresponding to the moisture class.

In an embodiment, the method is based on the awareness that it is sometimes difficult to provide and to process starting materials with a precisely specified standard moisture. Moisture classes are therefore used for processing the starting materials, and they are processed corresponding to the moisture class. In comparison to the use of starting materials whose moisture content lies somewhere within the predetermined moisture interval that is permitted and possible for processing, the process that depends on moisture classes yields a narrower breadth in the distribution of values of the moisture content, whereby surprisingly disproportionately positive results can be achieved for the base product. In processing different starting materials with respect to moisture content, it can be expected in principle that positive results for the output material can be achieved given suitably selected averages for an average moisture of the starting materials. The invention determined that processing depending on moisture classes yields disproportionately positive results in terms of reduced scrap and spatially homogeneous moisture distribution in the processed product.

In an embodiment, the moisture content can be adapted while processing by drying and/or moistening as a method step performed depending on the moisture class. In particular, this allows processing to be accelerated and the processing time to be reduced since drying or moistening only occurs as long as necessary depending on the moisture class. Moreover, and perhaps more important, is the advantage that output materials are created that possess a significantly more uniform moisture distribution for subsequent processing. Since the process parameters are matched to the moisture class, the moisture of the material after drying or moistening is distributed much more uniformly to a target moisture, i.e., provided with less variation than when the same process parameters are used for all moisture classes. Moreover, processing is thereby made easier and is less expensive.

In an embodiment of the inventive method, the moisture content of the final processed product is measured and the process is adjusted so that a homogeneous moisture distribution arises in the processed product. It is important to bear in mind here that the moisture content naturally always possesses a certain spread around an average. By selecting moisture classes and the process control depending on the moisture classes, the spread around the average decreases. A disproportionate improvement in the outcome is achieved by correspondingly rechecking the moisture content of the final processed product along with an adaptation, for example, in the form of a correction of the parameters for method management.

In an embodiment of the inventive method, a moisture measurement of the final processed product can be provided in that the average moisture contents and/or a spatial homogeneity of the moisture content is measured. The spatial homogeneity of moisture content can for example be measured by taking and measuring different samples of the processed product at different locations of the sample. A transmission measurement can also be used for the final processed product in which the final processed product is completely irradiated. The advantage of a transmission measurement is that more information is obtained on the spatial moisture distribution in the interior of the final processed product.

Proceeding from the moisture measurement in the processed product, the predetermined processing parameters are adapted or corrected depending on the average moisture content and/or the homogeneity of the moisture content. In this case, the processing parameters are optimized in order for example to ensure the homogeneity, i.e., the spatial uniformity of the moisture content in the processed product. It can also be provided to additionally undertake or discard individual processing steps such as for example storing the starting materials depending in each case on the moisture measurement in the finished product.

In an embodiment, the starting materials are different tobacco varieties. In production, it is for example known to process tobacco varieties such as Oriental, Virginia and Burly. The starting materials can also differ when the tobacco varieties are one and the same such as for example Burley or Virginia if they are for example processed originating from different tobacco bales or other preforms of the same variety.

In one preferred embodiment of the method according to the invention, a method step is provided for conditioning the starting materials. The conditioning is generally done using a conditioning drum in which the starting material is brought to a target moisture depending on its moisture class while specifying the parameters such as duration, moisture content and/or temperature. The conditioning step for the starting material is performed corresponding to the identified moisture class. To accomplish this, it can for example be provided that parameter sets for the conditioning process are selected corresponding to the moisture class initially identified for the starting material.

In an embodiment, the method step of conditioning with its parameters is corrected corresponding to the moisture measurement of the finished product. The measurement of the finished product can relate to the average moisture content and/or the spatial homogeneity of the moisture content in the product. In the correction of the parameters for the conditioning process based on the finished product, for example just the spatial homogeneity of the moisture content can for example be improved by for example changing the parameters for the conditioning process so that, while the average moisture content remains the same, the material at the end of the conditioning process possesses moisture values that are spatially more homogeneously distributed. In particular, transmission methods have proven to be particularly advantageous for measuring the finished end product. A transmission method investigates how the product behaves when the product is irradiated with microwaves. In this case, the microwaves pass through the product and are influenced by the moisture content and thus by the dielectric properties of water. A corresponding back calculation from the transmitted wave packets then permits conclusions about the average moisture content and/or also about the spatial distribution of the moisture along the direction of movement of the product. Depending on the embodiment of the transmission method, the transmitted beam can also be reflected, whereby the wave packet(s) then pass through the product twice.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further explained below with reference to an exemplary embodiment. In the figures:

FIG. 1 illustrates a graphical representation of the moisture content recorded over time and its homogeneity for pipe tobacco in the upper part and a relative distribution of the moisture values in the pipe tobacco in the lower part; and

FIG. 2 illustrated a schematic representation of an embodiment of a method for processing of Virginia/Oriental and Burley tobacco.

DETAILED DESCRIPTION OF THE INVENTION

The upper part of FIG. 1 shows the development of the moisture value [%] for the time just before 11 o'clock to a time just after 12 o'clock. The moisture value fluctuates in this case around 11 o'clock and otherwise possesses an average of approximately 17.5%. At the same time, the lower part of FIG. 1 records how homogeneous the moisture is in the pipe tobacco. In this case, the dark band 12 running around the average designates a range in which lies 68% of the measured values of 1−σ. The lighter, outside band 14 designates the values in which lies approximately 95% of the measured values of 2−σ. This distribution is clear in the depiction of the relative moisture in the bottom part of FIG. 1. A frequency distribution of the moisture values is plotted here for each relative moisture value. The frequency distribution is obtained for each relative moisture value by measuring with the sensor for a certain length of time, for example 5 or 10 minutes at a measuring point. It is clearly discernible that for example a moisture value, 16, arises in the measurement of the base product with a measured value of approximately 15.5%; these are the measured values occurring at 11 o'clock. It is also clearly discernible that a very large and wide distribution is ascribable to these measured values, which reveals an end product with an inhomogeneous moisture distribution. Consequently with the method according to the invention, not only does the average moisture lie at the desired value, the moisture is also homogeneously distributed in the base product, and for example 90% lies within the given moisture window 18.

FIG. 2 describes the processing of two tobacco varieties in a so-called primary process. The starting points in this case are the Oriental and Virginia 10 tobacco varieties and the Burley 12 tobacco variety that each have a moisture content (MC) of 9% to 11%. Oriental is added to the process at a mass flow rate of for example 1.5 t/h; Virginia is added at a mass flow rate of 5 t/h. Burley 12 can be added at a comparable mass flow rate. The bales of the packed tobacco are opened, and the tobacco is taken out of the bales and cut if applicable. In this case, an overall volumetric flow rate for Oriental/Virginia 10 of 6.5 t/h occurs with an average moisture of 10%. The temperature is 25° C.

In a following processing step 14, 16, both tobacco streams are conditioned, wherein 455 L water per hour is added for this. The base product possesses a greater mass due to the absorbed water of 7.31 t/h and a moisture content of 20% at an initial temperature of 65° C. In subsequent mixing and storage 18, 20, the tobacco streams are stored and prepared for subsequent processing.

For the Burley 12 tobacco variety, a step of casing 22 follows the storage option 20. In casing, a liquid mixture of water, glycerin and other substances is added to the tobacco in order to coat the individual tobacco fibers. In the context of casing, the moisture content is increased from 20% to 36% by supplying the corresponding amount of moisture. In a following drying step 24, the moisture content is then reduced to 18% and then again adapted to 20% moisture content in subsequent recasing 26. Mixing and storage 28 then follows for Burley 12. Just as with the Virginia/Oriental 10 tobacco variety, mixture and storage 18, 28 do not change the moisture content which instead remains unchanged at 20%. This is followed by a final mixing process 30 in which the moisture content also remains unchanged at 20%. The mixture produced in this way is then supplied to a final cutting and drying step 32. In so doing, the moisture content is reduced from 20% to 13%. The final processed mixture in terms of moisture is then supplied to a flavoring step 34 in order to be stored in a silo 36 with a constant moisture. From the silo 36, the tobacco mixture is then supplied with a moisture content of 13% to cigarette production 38.

The method according to the invention provides measuring the moisture content of the tobacco 10, 12 as starting material and dividing it into for example three moisture classes A and B, wherein for example A corresponds to a moisture content of 9.0% to 9.9%, and B corresponds to a moisture content of 10.0% to 11%. The Virginia tobacco 10 can for example have a significantly greater mass flow in the process so that preferably six moisture classes I to VI are formed here. Class I corresponds to a moisture of 9.0% to 9.5%, II to 9.6% to 10.0% . . . VI to 10.5% to 11.0%.

In the method according to the invention, as explained above, a division into different moisture classes is performed. The moisture classes can be graded against each other with varying fineness. In one possible embodiment of the method, the division into moisture classes occurs directly before the first conditioning steps 14 and 16. In this case, the parameters for the conditioning process can be selected corresponding to the moisture class. If for example a Virginia tobacco 10 of moisture class V is supplied to a conditioning step 14, parameters are correspondingly selected in the conditioning cylinder that for example can be designed as a direct conditioning cylinder (DCC). These parameters then differ from the parameters with which the conditioning cylinder is controlled when there is another moisture class. Through the moisture-class-dependent controlling of the conditioning steps 14 and 16, a moisture content of 20% arises in process steps 40 and 42 whose distribution has a significantly thinner width. If a normal distribution is assumed for the distribution of the moisture values, the width of the distribution of the moisture values can be determined as a full width at half maximum. Since conditioning steps 14 and 16 are carried out depending on the moisture class, a moisture distribution of the tobacco stream therefore arises with a moisture value of 20% that is significantly narrower than the full width at half maximum when the tobacco stream is carried out without moisture classes and without moisture-dependent parameter control.

For the Burley 12 tobacco variety, a corresponding division into moisture classes can also occur in method steps 44 and 46. The moisture content of 20% is raised to 36% with the casing method step 22. In this case, it is possible to measure in method step 44 the tobacco stream supplied to method step 22, and to control method step 22 corresponding to the moisture class. The parameters determining method step 22 in this case such as for example the supplied amount of water (in liters) are also adjusted corresponding to the measured moisture class. The Burley tobacco 12 can also be correspondingly divided into moisture classes for the dryer step 24, and for example the drying time can be correspondingly adapted in method step 24. In principle, to increase the moisture content from 18% to 20% in method step 26, it is also possible to control this method step corresponding to a moisture class measured in method steps 48. Likewise, the moisture content can be measured in the cutting and drying step 32 for the final mixing 30 in method step 50, and for example the duration and drying temperature of the drying process can be correspondingly controlled.

In addition to the above-explained division into moisture classes that always occurs at the input side and the corresponding moisture-class-dependent controlling of the subsequent method step, it is also possible to measure the average moisture and/or the homogeneity of the moisture distribution of the end product after the storage silo 36 in method step 52. Based on the moisture measurement of the finished product in method step 52, individual parameters can then be corrected in the process. If for example it is found that the average moisture of 13% is spot on in the measurement in method step 52 but there is a certain amount of spatial inhomogeneity in the moisture distribution, however, this can be used to change for example individual method steps. For example the homogeneity of the moisture distribution can accordingly be improved if the drying temperature is reduced and the drying time is lengthened in a drying step 24, 32. Also when combining the tobacco in method steps 14 and 16, it is possible to reduce the supply rate of the liquid and simultaneously lengthen the process duration for the conditioning step 14 and 16. Based on the moisture measurement of the finished product 52, corrections are made in this case to the parameter values for the process steps, wherein the parameters were always corrected in this case that are dependent on the moisture classes measured at the input side of the process step.

LIST OF REFERENCE SIGNS

-   Virginia tobacco 10 -   Burley tobacco variety 12 -   Conditioning steps 14 and 16 -   Processing step 14, 16 -   Mixing and storage 18, 20, 28 -   Casing method step 22 -   Drying step 24 -   Recasing method step 26 -   Mixing process 30 -   Silo 36 -   Cigarette production 38 -   Method steps 44 and 46 -   Product 52 

1-10. (canceled)
 11. A method for processing at least two starting materials into a final processed product, wherein a predetermined moisture interval is provided for each starting material, the method comprising: subdividing each moisture interval into two or more moisture classes; measuring a moisture content for each starting material prior to processing; assigning each starting material to one of the two or more moisture classes, wherein each of the two or more moisture classes comprises a range of values for the moisture content of the starting material within the moisture interval; processing each starting material depending on the moisture classes; determining a moisture measurement of the final processed product; and adapting one or more processing steps based on the measuring results for the final processed product to achieve a homogeneous moisture distribution in the final processed product.
 12. The method according to claim 11, wherein the processing of the starting materials individually and separately includes achieving a target moisture of the starting materials.
 13. The method according to claim 11, wherein the moisture measurement of the final processed product measures at least one of: (1) an average moisture content; and (2) a spatial homogeneity of the moisture content.
 14. The method according to claim 11, wherein processing parameters for at least one processing step are corrected depending on the moisture measurement of the final processed product.
 15. The method according to claim 11, wherein at least one processing step is additionally provided depending on the moisture measurement of the final processed product.
 16. The method according to claim 11, wherein at least one processing step is omitted depending on the moisture measurement of the final processed product.
 17. The method according to claim 11, wherein the starting materials comprise at least one of: (1) different tobacco varieties; (2) a tobacco variety from different bales; and (3) another preform.
 18. The method according to claim 11, further comprising conditioning the starting materials according to parameters that are selected depending on the moisture classes to bring the starting materials to a target moisture, wherein the parameters comprise at least one of duration, moisture, and temperature.
 19. The method according to claim 18, wherein the conditioning of the starting materials is corrected according to the moisture measurement of the final processed product.
 20. The method according to claim 18, wherein the conditioning of the starting materials depends on at least one of an average moisture content and a spatial moisture distribution measured for the final processed product. 